Inside StopFlex Long-Fiber Carbon Ceramic Brake Disc Manufacturing
We tightly weave aerospace-grade T800 carbon fibers into a lattice (like high-tech carpet!), creating a lightweight disc "skeleton". Every thread is precision-aligned to handle insane braking forces. Each fiber layer gets coated in a secret sauce: carbon powder + silicon carbide + resin, dried, then stacked with reinforcement mesh—15 layers thick (think bulletproof lasagna!). This 30mm sandwich forms the disc’s core. We press-and-bake the stack at 180°C & 25 MPa (that’s 3,600 PSI!) for 2 hours. This fuses everything into a rock-solid "green body" (density: 1.6 g/cm³)—lighter than aluminum, stronger than steel. The disc meets molten silicon at 1,550°C (sun-surface heat!) in a vacuum chamber. Silicon soaks into every pore, reacting to form silicon carbide ceramic—nature’s armor. Result? A disc that shrugs off 1,500°C track heat. After cooling, we machine ventilation channels and diamond‑grind the surface to a mirror finish (≤0.02mm). The result? A disc with perfect cooling, precise fit, and minimal dust—ready for high‑performance use. We batch‑test every StopFlex carbon‑ceramic disc through brutal bench cycles: from 200 km/h down to zero, over and over, non‑stop for a full hour. During this ordeal, temperatures hover around 900 °C, and the disc must hold a rock‑steady friction coefficient from start to finish. That’s how we guarantee your brakes stay sharp—whether shredding laps or stopping on the street.Inside StopFlex Long-Fiber Carbon Ceramic Brake Disc Manufacturing
Built for Safety. Driven by Performance.
Unlike typical mass-market discs that rely on chopped strands, StopFlex harnesses the strength of continuous long-carbon fiber reinforcement. We weave these high-strength fibers into a complex 3D preform, establishing a structural toughness that fragmented materials simply cannot match.
Once shaped, the disc undergoes a critical vacuum silicon infiltration process at 1,700°C. This converts the preform into a robust C/SiC composite, ensuring the material is dense, stable, and ready for extreme heat.
This advanced process yields discs capable of resisting cracking at temperatures up to ~1,800°C. For the discerning driver, this means superior heat management and unwavering structural integrity, delivering consistent, supercar-grade braking power.
Step 1
Carbon Fiber Weave
Fiber Frame
Step 2
Resin & Reinforcement
Layered Armor
Step 3
Pressure Baking
Density Locked
Step 4
Silicon Fusion
Born in a Vacuum
Step 5
Mill & Polish
Race-Ready Refinement
Step 6
Quality Control
Rigorous Brake Testing
